Method and apparatus for assembling terminals and wires



METHOD AND APPARATUS FOR ASSEMBLING TERMINALS AND WIRES Filed Dec. 18,1961 J- R. FILSON April 12, 1966 2 Sheets-Sheet IL,v

METHOD AND APPARATUS FOR ASSEMBLING TERMINALS AND WIRES Filed Dec. 18,1961 J. R. FILSON April 12, 1966 2. Sheets-Sheet 9v United States Patent3,245,246 METHOD AND APPARATUS FOR ASSEMBLING TERMINALS AND WIRES JohnRichard Filson, Medford, NJ., assignor to Positive Connector Co.,Medford, N.J., a corporation of Delaware Filed Dec. 18, 1961, Ser. No.159,991 4 Claims. (Cl. 72-401) The present invention relates to a novelmethod and apparatus for forming sheet material articles, and morespecifically to a novel method and apparatus for assembling andconnecting articles such as terminals and the like with elongated wiresor other similar workpieces.

While it will become apparent that certain features of the presentinvention may be adapted for forming or processing a wide variety ofarticles, disclosure of the present invention will be facilitated bydescribing an embodiment which is especially suitable for forming andsecuring sheet metal terminal devices or articles to ends of electricalwires. The present invention contemplates the provision of a pluralityof terminal devices disposed in side by side parallel relationship andinterconnected with each other in a long strip. Each of the terminalscomprises a socket portion, fingers or other suitable means adapted tobe crimped around an end portion of a wire. It is further contemplatedthat the strip is to be advanced so that each terminal is successivelylocated at a work station at which a wire or the like is inserted intoits socket portion or other corresponding means whereupon the terminalis crimped onto the wire.

An important object of the present invention is to provide a novelapparatus capable of efiiciently and effec tively forming or crimping aterminal or similar device whereby to promote more economical processingof such articles.

A more specific object of the present invention is to provide a novelmethod and apparatus for forming or crimping workpieces in a manner suchthat the workpieces are readily disengaged from the apparatus after aforming or crimping operation.

A still further specific object of the present invention is to provide anovel apparatus for forming or crimping workpieces and having die meansconstructed for releasing the workpieces after a forming or crimpingoperation without the need for applying any appreciable stripping forceto the workpieces and without the need for utilizing any strippingmechanisms whereby injury to the formed or crimped workpieces will beavoided and the apparatus is simplified and more economical.

Another object of the present invention is to provide a novel method andapparatus for assembling a plurality of terminals or the like in stripform with a plurality of wires, which method and apparatus facilitatescontrol and feeding of the strip of terminals and provides an improvedconnection with the wires.

Other objects and advantages of the present invention will becomeapparent from the following description and the accompanying drawingswherein:

FIG. 1 is an elevational view showing apparatus incorporating featuresof the present invention;

FIG. 2 is a fragmentary view of a portion of the apparatus shown in FIG.1 partially broken away in order to show certain details more clearly;

FIG. 3 is similar to FIG. 2 but shows the manner in which the apparatusfunctions for releasing a workpiece after a forming or crimpingoperation;

FIG. 4 is a fragmentary plan view of the apparatus shown in 'FIG. 1;

FIG. 5 is a fragmentary sectional view taken generally along line 5-5 inFIG. 1;

FIG. 6 is a fragmentary sectional view taken generally along line 6-6 inFIG. 4;

FIG. 7 is a fragmentary perspective view showing a portion of a terminalstrip which maybe [processed in accordance with the present invention;

FIG. 8 is a perspective view showing a terminal assembled with a Wire inaccordance with the present invention; and

FIG. 9 is a fragmentary sectional view taken along line 9-9 in FIG. 8.

Referring now more specifically to the drawings wherein like parts aredesignated by the same numerals throughout the various figures, anapparatus 10 incorporating features of the present invention includes apunch press or the like *12 which may be of any known construction. Thepunch press need not be shown or described in detail and, as will beunderstood, it may include a base or bolster 14 and a reciprocable ram16, only fragmentary portions of which are shown in FIG. 1.

In accordance with a feature of the present invention, a mechanism 18-is associated with the punch press 12 for feeding and crimpingsuccessive articles or terminals 20 which are joined together as shownbest in FIGS. 4 and 7 to provide a continuous strip 22. Each of theterminals 20 comprises a socket portion adapted to receive an end ofa-wire 24 as shown in FIGS. 8 and 9. In the particular embodimentdisclosed for the purpose of illustrating the invention, this socketportion includes a first generally U-shaped section having oppositelydisposed finger portions 26 and 28 adapted to be wrapped around andcrimped against a sheath 30 of insulating material on the wire 24. Inaddition the socket means includes a second generally U-shaped sectionhaving oppositely disposed finger portions 32 and 34 which are adaptedto be formed around and crimped on an exposed end of the wire 24.

-In order to enchance the electrical and mechanical connection betweenthe terminal and a wire, it is contem-.

plated that the finger elements '32 and 34 will he crimped and embossedin a manner such that a rib 36 is formed as shown in FIGS. 8 and 9. Therib 36 traverses end portions of both of the finger elements 32 and 34and is disposed !between opposite margins 38 and 40 which are firmlycrimped or compressed against the wire 24. As shown best in FIG. 9, theinner surface of the rib 36 tends to conform to the outer surfacewhereby a groove 42 is provided. When the terminal is crimped onto thewire, a portion of the wire will be forced or extruded into the groove42 for enhancing the mechanical and electrical connection between theterminal and the wire. At the same time there is no pinching orindenting of the wire which might cut or damage the wire and actuallyweaken the connection.

Each of the terminals 20 has an end portion or connecting section 44integrally joined to an elongated narrow connecting strip 46. When aterminal has been crimped onto a wire as shown in FIGS. 8 and 9, it maybe separated from the strip 46 by shearing the connection section 44.

It is contemplated that the terminals 20 in the strip' 22 may be formedfrom a fiat band of stock material by utilizing suitable stamping andforming dies, not shown.

It has been found that when the band of stock material is stamped andformed to provide the individual terminals 20 joined by the narrow strip46, stresses are imparted to the strip 46 which tend to cause the strip46 to curl about its narrow edge to which the terminals are integrallyjoined. Such curling of the strip makes subsequent handling and feedingof the strip relatively difficult and may cause jamming of theapparatus. It has been found however, that any tendency of the strip 46to curl may be minimized and substantially eliminated by swaging andslightly embossing areas 48 traversing the integral junctions betweenthe sections 44 and the strip 46. Preferably, the swaged and slightlydeflected areas 48 are formed simultaneously with the stamping andforming of the terminals 20.

The mechanism 18 comprises a die structure capable of forming andcrimping the socket portion or finger elements 26-28 and 32-34 ofsuccessive terminals 20. Thus, in the embodiment shown, the diestructure includes a pair of anvil elements 50 and 52 shown in FIGS. 1,2 and 6 and against which the pairs of fingers 26-28 and 32-34 arerespectively adapted to be crimped. The anvil elements 50 and 52 aremounted in a block 54 suitably secured to the base means 14 of the punchpress. As shown in FIGS. 1 and 2, the anvil elements have a widthsubstantially equal to the desired width of a crimped socket portion ofa terminal. Furthermore, the anvil elements and the die holder or block54 are formed for providing recesses 56 and 58 at opposite sides of theanvil elements and respectively having guide surfaces 60 and 62 spaced apredetermined distance from opposite sides of the anvil elements.

The die structure further includes a block or holder 64 suitably securedto a head member 65 slidably supported by guide rods 67 and 69 andconnected to the ram 16 of the punch press. Vertically disposed diemembers 66 and 68 are mounted and carried by the block 64 in the mannerdescribed more in detail below. The die members 66 and 68 arerespectively aligned with the anvil elements '50 and 52 for forming orcrimping the socket portions or pairs of fingers 26-28 and 32-34. Agroove 71 is provided in the die element 68 for forming the rib 36 on aterminal.

When the ram 16 is in a down position, as shown in FIGS. 1 and 2, aterminal or article will be crimped between the opposing upper and lowerdie elements. In order to insure a compact final article and goodmechanical and electrical contact between the terminal and the entireperiphery of a wire, means are provided for engaging and confiningopposite sides of a terminal socket portion while the socket portion isbeing formed and crimped between the aforementioned opposing pairs ofdie elements. This means comprises a pair of blade members 70 and 72carried by the block 64 at opposite sides of the die elements 66 and 68as shown best in FIGS. 1-3. Lower end portions of the backup blademembers 70 and 72 project below the lower ends of the upper die elements66 and 68 and are adapted to enter the recesses 56 and 58 as will bedescribed more in detail below. In accordance with an important featureof the present invention, upper end portions of the blade members 70 and72 are formed with circular enlargements 74 and 76 respectively. Theenlargements 74 and 76 are pivotally disposed in complementary circularrecesses 78 and 80 formed in the block 64. The blade members 70 and 72extend downwardly from the recesses 78 and 80 through passageways whichare partially defined by stop or abutment surfaces 82 and 84, whichabutment surfaces are respectively offset from opposite sides of the dieelements 66 and 68 a distance slightly greater than the width ofthickness of the downwardly extending portions of the blade members 70and 72. With this structure, the blade members 70 and 72 are adapted topivot between the parallel position shown in FIG. 2, or the spread apartor flaring position shown in FIG. 3.

When the ram 16 of the punch press moves downwardly at the start of aworkpiece forming or crimping operation, the lower ends of the blademembers 70 and 72 enter the recesses 56 and 58 as shown in FIGS. 1 and2. Such entry is facilitated by providing the lower ends of the blademembers with beveled cam surfaces 86 and 88. These cam surfaces incombination with the stop or abutment surfaces 82 and 84 which limitoutward pivotal movement of the blade members, assure entry of the blademembers into the recesses without undue interference with the upper edgeof the block 54. The blade members 70 and 72 have a thicknesssubstantially equal to but slightly less than the width of the recesses56 and 58. As a result, the blade members will be held by the guidesurfaces 60 and 62 substantially against opposite sides of the diemembers for positively confining opposite sides of a workpiece during aforming or crimping operation.

It is important to note that when the ram returns toward its upperposition, upon the completion of a forming or crimping downwardlystroke, the lower end portions of the blade members will be completelywithdrawn from the recesses 56 and 58 and disengaged from the guidesurfaces 60 and 62 sufficiently to enable the blade members to pivotoutwardly to the position shown in FIG. 3. Upon such pivotal movementwhich may occur freely and which, in fact, will be positively urged bypressure from a workpiece, the workpiece will be immediately freed andwill drop from between the blade members. In other words, theconstruction is such that a workpiece will automatically be freed at theend of a forming or crimping operation so that it may be easily removedby an operator without forcing and without the need for any ejectingmechanism.

It is understood, of course, that between each downward stroke of theram 16, one of the workpieces or terminals 20 is advanced to a positionon the anvil or lower die elements 50 and 52, and a wire 24 is insertedeither manually or by means not shown into the socket portion of theterminal. In certain instances it may be desirable to assemble Wires ofditferent diameters with the terminals. Therefore, in accordance withanother feature of the present invention, means is provided forselectively positioning the upper die elements 66 and 68 for adaptingthe structure to crimp the terminals around Wires of differentdiameters. As shown in FIGS. 1-4 and 6, this means comprises cam members90 and 92 disposed in complementary slots formed in the block 64transverse ly of and intersecting upper ends of vertical slots in whichthe upper die elements 66 and 68 are disposed. The cam member 90 isprovided with an inclined surface 94 engageable with a complementaryupper end surface of the die element 66, and the cam member 92 is formedwith a similar inclined surface 96 which engages and backs up acomplementary upper end surface of the die element 68. With thisstructure, the die elements 66 and 68 may be selectively andindependently adjusted downwardly and upwardly when the cam members 90and 92 are advanced or retracted. In order to enable adjustment of thecam members 90 and 92, adjustment screws 93 and 100 are provided, whichscrews are threaded into suitable aperture means provided adjacent thecam members. Flanges 102 and 104 are provided on the adjustment screws,which flanges project into notches 106 and 108 respectively in outer endportions of the cam members 90 and 92 for interconnecting the adjustmentscrews with the cam members.

The means for feeding the strip 22 to the die structure is shown best inFIGS. 1, 4 and 5. This means comprises an elongated guide 110 to whichthe strip is fed from a suitable source of supply such as a reel, notshown, supporting a coil of the. strip 22. A guide bar 112 shown in FIG.1 is adapted to overlie the strip and hold the strip down on the guide110.

A pusher element or pawl 114 having an adjustable and downwardlyprojecting pointed end member 116 is provided for engaging eachsuccessive terminal 20 in the strip 22 and pushing or feeding the stripforwardly a distance equal to the spacing between the terminals 20during each upward stroke of the ram 16. As shown in FIGS. 1 and 4, theend member 116 of the pawl is adjustably secured by a screw 118 to themain portion of the pawl so that the over-all effective length of thepawl can be adjusted for accommodating different strips 22 havingarticles or terminals spaced apart different distances.

The pawl 114 is pivotally carried by a pin 120 which in turn extendsthrough a slot 122 in a link 124. Preferably, a sleeve or bearingelement 126 is assembled over the pin or screw 120 for pivotallysupporting the pawl member 114 on the screw. As shown best in FIG. 5, aspring 128 is coiled around a portion of the bearing member 126 and hasopposite end portions fixed respectively to the pawl member 114 and tothe link 124 in a manner which resiliently biases the pawl memberdownwardly or in a clockwise direction as viewed in FIG. 1. Thus, thepawl member is continuously resiliently biased downwardly for engagementwith the terminals 20 of the strip 22 so that the pawl will be effectivefor pushing the strip when the pawl is moved toward the right as viewedin FIG. 1 in the manner described below. At the same time the pawl isadapted to slip back over the terminals in the strip 22 when the pawlmember is moved toward the left as viewed in FIG. 1 during thenon-feeding stroke.

An upper end of the link 124 is pivotally supported by a pin 130 whichis mounted on an upstanding bracket 132. Another link 134 is providedwith a bifurcation which is also pivotally supported on the pin 130. Asshown in FIGS. 4 and 5 the bifurcated end portion of the link 130embraces the upper end of the link 124. Furthermore, the bifurated endportion of the link 130 extends laterally beyond a side of the link 124and carries an abutment element or pin 136 which is slightly spaced frombut engageable with the adjacent side or edge of the link 124. Thearrangement is such that when the link 134 is in the position shown inFIG. 1, the abutment element or pin 136 is substantially disengaged fromthe edge of the link 124. However, upon pivotal movement of the link 134in an upward or counterclockwise direction as viewed in FIG. 1, the pin136 will move downwardly into engagement with the link 124 for pivotingthe link 124 in a counterclockwise direction and thereby shifting thepawl member 114 toward the right as viewed in FIG. 1 for feeding thestrip 22. In order to return the link 124 to the position shown in FIG.1 against a fixed stop member 138 upon the completion of a feedingstroke, a spring 140 is provided, which spring is mounted between thelink 124 and a tubular abutment 142 carried by and depending from theunderside of the link 134.

The link 134 is operated in timed relationship with the ram 16 so thatthe strip 22 is intermittently fed in time with the terminal crimping orforming operations. In order to actuate the link 134 in this manner, apin 144 is mounted on a bracket 146 secured to the head member 65. Thispin extends through an elongated slot 148 provided in an end of the link134.

While it is believed that the operation of the above described apparatusis clear, a brief resume of the method of forming and assemblingarticles such as terminals and wires in accordance with the presentinvention is as follows. A blank strip of stock material is firststamped to the strip 22 which comprises a plurality of individualarticles or terminals integrally joined together in side-bysiderelationship by a narrow connecting strip and having junctions with thenarrow connecting strip cold worked and slightly indented or embossedfor causing the strip to remain substantially straight. Then the strip22 is intermittently fed for successively positioning the articles orterminals 20 at the work station between the lower die elements oranvils 50-52 and the upper die elements 66-68. When a terminal isproperly positioned at the work station, a wire is inserted into thesocket portion of the terminal whereupon the apparatus is actuated tomove the ram 16 downwardly through a work stroke. As the ram movesdownwardly, the backup or side blades 70 and 72 enter the recesses 56and 58 so that the sides of the terminal are positively confined andthen the upper die elements 66 and 68 engage the terminal for formingand crimping the terminal into the condition shown best in FIGS. 8 and9. If desired, the die structure may be provided with an element forsevering a terminal from the strip during the crimping operation, or theterminal may be separated at a later work station. When the ram issubsequently raised, the side or backup blade members 70 and 72 are freeto spread apart for immediately releasing the formed and crimped articlewhich is then removed as the next terminal is automatically fed to thework station.

While the preferred embodiment of the present invention has been shownand described herein, it is obvious that many details may be changedwithout departing from the spirit and scope of the appended claims.

The invention is claimed as follows:

1. An apparatus for processing a workpiece comprising means for feedinga workpiece along a predetermined path of travel to a work station,first and second opposing relatively reciprocable workpiece engageabledie means at said work station for engaging and processing a workpiecepositioned therebetween, said first die means being reciprocablydisposed at one side of said path of travel and said second die meansbeing disposed at an opposite side of said path of travel, side means atopposite sides of said first and second die means for confining oppositesides of a workpiece being engaged by said first and second means, saidside means being reciprocable with said first die means, at least one ofsaid side means being relatively movable away from the other forreleasing a processed workpiece from therebetween, said side meansincluding portions extending across said path of travel and along saidsecond die means when said workpiece is being engaged by both of saidfirst and second die means, and abutment means adjacent said second diemeans for engaging said portion of said one side means and retainingsaid one side means against moving when said die means are engaging aworkpiece.

2. An apparatus, as defined in claim 1, which includes means pivotallymounting both of said side means for movement toward and away from eachother.

3. An apparatus as defined in claim 1 for crimping a terminal onto awire, wherein one of said die means includes a groove means thereon forforming an outwardly projecting rib having a concave inner surface insaid terminal and for simultaneously forming a portion of the wireagainst said concave surface.

4. An apparatus for processing a workpiece comprising first and secondopposing relatively reciprocable die means for engaging and processing aworkpiece positioned therebetween, side members respectively disposed atopposite sides of said first and second die means for confining oppositesides of a workpiece being engaged by said first and second die means,means pivotally supporting said side members for movement toward andaway from each other, means for retaining said side members againstmovement away from each other when said first and second die means arerelatively moved toward each other for processing a workpiece and forreleasing said members for movement away from each other when said firstand second die means are relatively moved away from each other afterprocessing a workpiece, means adjustably supporting one of said'diemeans,

said adjustable supporting means including a member having an inclinedsurface engaging and backing up said one die means, and means foradjustably positioning said last mentioned member.

References Cited by the Examiner UNITED STATES PATENTS 2,854,648 9/1958Berg 339-276 2,878,854 3/1959 Batchelier 1531 2,929,046 3/1960 Berg339-276 2,948,953 8/1960 Rayburn 29-155.55 2,954,602 10/1960 Derby29-1935 8 8/1961 Burdick 29-1935 10/1961 Cootes 153-1 11/1961 Forney29155.55 8/1962 Batcheller 1531 5/1963 Aquillon 1531 FOREIGN PATENTS1/1910 France.

CHARLES w. LANHAM, Primary Examiner.

WILLIAM J. STEPHENSON, Examiner.

1. AN APPARATUS FOR PROCESSING A WORKPIECE COMPRISING MEANS FOR FEEDINGA WORKPIECE ALONG A PREDETERMINED PATH OF TRAVEL TO A WORK STATION,FIRST AND SECOND OPPOSING RELATIVELY RECIPROCABLE WORKPIECE ENGAGEABLEDIE MEANS AT SAID WORK STATION FOR ENGAGING AND PROCESSING A WORKPIECEPOSITIONED THEREBETWEEN, SAID FIRST DIE MEANS BEING RECIPROCABLYDISPOSED AT ONE SIDE OF SAID PATH OF TRAVEL AND SAID SECOND DIE MEANSBEING DISPOSED AT AN OPPOSITE SIDE OF SAID PATH OF TRAVEL, SIDE MEANS ATOPPOSITE SIDES OF SAID FIRST AND SECOND DIE MEANS FOR CONFINING OPPOSITESIDES OF A WORKPIECE BEING ENGAGED BY SAID FIRST AND SECOND MEANS, SAIDSIDE MEANS BEING RECIPROCABLE WITH SAID FIRST DIE MEANS, AT LEAST ONE OFSAID SIDE MEANS BEING RELATIVELY MOVABLE AWAY FROM THE OTHER RELEASING APROCESSED WORKPIECE FROM THEREBETWEEN, SAID SIDE MEANS INCLUDINGPORTIONS EXTENDING ACROSS SAID PATH OF TRAVEL AND ALONG SAID SECOND DIEMEANS WHEN WORKPIECE IS BEING ENGAGED BY BOTH OF SAID FIRST AND SECONDDIE MEANS, AND ABUTMENT MEANS ADJACENT SAID SECOND DIE MEANS FORENGAGING SAID PORTION OF SAID ONE SIDE MEANS AND RETAINING SAID ONE SIDEMEANS AGAINST MOVING WHEN SAID DIE MEANS ARE ENGAGING A WORKPIECE.